Amorphous Core Dry Transformer Holding Apparatus
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Solution Overview
Problem
Dry power transformers using amorphous core material face increased core losses due to mechanical sensitivity, limiting their load capability and efficiency compared to oil-filled transformers.
Innovation Solution
A dry transformer design featuring a holding apparatus to suspend and fix primary and secondary windings around an amorphous core, using strip material wound into a three-limb or five-limb configuration with clamping elements to minimize mechanical stress on the core, and incorporating insulating coatings for shock absorption and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If amorphous core material is used in dry transformers, then hysteresis losses are kept low, but mechanical sensitivity increases leading to increased core losses
Solution Approach 1:
The holding apparatus incorporates cushioning elements or compliant features that are designed in advance to absorb and dampen mechanical shocks and vibrations before they can reach the amorphous core. This protective mechanism is built into the support structure to preemptively mitigate mechanical stress.
Solution Approach 2:
The holding apparatus allows for adjustment of mechanical parameters such as clamping force, positioning, and support stiffness. These parameters can be optimized to match the specific mechanical sensitivity characteristics of the amorphous core material, providing tailored support that minimizes stress while maintaining structural integrity.
2Reliability
If holding apparatus acts on end faces of winding former, then windings are fixed securely, but mechanical stress may be transmitted to amorphous core
Solution Approach 1:
The function of holding and fixing is extracted from the core support structure and assigned to a separate, dedicated holding apparatus. This separation allows the core to be supported independently without direct mechanical constraints from the winding former or external mounting, isolating it from stress transmission.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively reduces core losses and enhances load capability by avoiding mechanical loads on the amorphous core, improving the efficiency and performance of dry transformers while maintaining low hysteresis losses.
Implementation Method 1
Core materials having a very low hysteresis loop can therefore be used in order to keep the hysteresis losses as low as possible
Implementation Method 2
The no-load losses are governed primarily by the induction and the nature of the core
Implementation Method 3
amorphous material is highly pressure-sensitive, as a result of which this can result in an increase in the core losses
Implementation Method 4
the heat losses which were absorbed by the oil in the case of power transformers with an oil filling and were emitted via suitable cooling surfaces or separate coolers, are dissipated by air convection
Data Source
AI summary
A transformer of dry design is disclosed having a core composed of amorphous material, which is sensitive to mechanical loads, having at least one winding former which surrounds the core and is in each case formed from at least one primary winding and secondary winding, and having at least one holding apparatus. A method for transformer production is also disclosed, wherein the holding apparatus is used to fix the at least one primary winding and secondary winding in each case and for this purpose it acts on each of the end faces of the at least one winding former.